Product portion enrobing machines and methods

ABSTRACT

An apparatus for enrobing a product portion can include at least one polymer spray head adapted to create at least one flow of polymeric fibers to produce at least one polymer enrobing zone and a conveyor system adapted to move at least one product portion from at least one position below at least one polymer enrobing zone and to at least one position above at least one polymer enrobing zone to drop each product portion through one or more polymer enrobing zones a plurality times at different orientations to enrobe each product portion with polymeric fibers.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation Ser. No. 15/594,190, filed May 12,2017, which is a divisional of application Ser. No. 14/213,108, filed onMar. 14, 2014, which claims the benefit of priority under 35 U.S.C. §119(e) to U.S. Application No. 61/786,295 filed Mar. 14, 2013, theentire contents of each of which are incorporated herein by reference.

FIELD

This disclosure generally relates to processes and machines for enrobingproduct portions with polymeric fibers. In some cases, portions ofsmokeless tobacco can be enrobed in polymeric fibers to create afiber-wrapped smokeless tobacco-product.

BACKGROUND

Smokeless tobacco is tobacco that is placed in the mouth and notcombusted. There are various types of smokeless tobacco including:chewing tobacco, moist smokeless tobacco, snus, and dry snuff. Chewingtobacco is coarsely divided tobacco leaf that is typically packaged in alarge pouch-like package and used in a plug or twist. Moist smokelesstobacco is a moist, more finely divided tobacco that is provided inloose form or in pouch form and is typically packaged in round cans andused as a pinch or in a pouch placed between an adult tobacco consumer'scheek and gum. Snus is a heat treated smokeless tobacco. Dry snuff isfinely ground tobacco that is placed in the mouth or used nasally.

Smokeless tobacco can be pouched in a permeable fabric using a pouchingmachine where a supply of pouching material is sealed around a depositof smokeless tobacco material. Such a pouch holds the tobacco in place,while at the same time letting the flavors and substances of the tobaccopass through the walls of the pouch and into the adult tobaccoconsumer's mouth. A conventional pouching machine may form a supply ofpouching material around the tube, seal the edges of the pouchingmaterial to form a tube of pouching material, form a cross-seal to forma bottom of the pouch, deliver an amount of smokeless tobacco throughthe tube and into the bottom-sealed pouch, move the bottom-sealed pouchoff the tube, and form a second cross-seal above the smokeless tobaccoto close the pouch. The second cross-seal can also be used as the bottomseal for a subsequent pouch as the process continues. Individual pouchescan be cut at the cross-seals. FIG. 6B depicts an example of a pouchedsmokeless tobacco product made using a traditional pouching machine.

SUMMARY

Methods and machines provided herein can be used to enrobe a productportion (e.g., a smokeless tobacco-product portion) with polymericfibers. Polymeric fiber enrobed product portions can be used in a numberof consumer products, such as smokeless tobacco products and herbalproducts (e.g., tea). As compared to a conventional pouch made using aconventional pouching machine, a fiber-wrapped smokeless tobacco portionmade using the methods and machines provided herein can have an improvedmouth feel (e.g., no discernible seams), be more permeable, and/or bemore chewable. Methods and machines provided herein can be used toefficiently and reliably enrobe multiple product portions. In somecases, elastomeric enrobed product portions produced by methods andmachines provided herein can provide the unique property of allowing anadult tobacco consumer to reduce or increase a packing density of anelastomeric enrobed product portion during use, which can impact a rateof flavor release. A higher packing density can reduce a rate of flavorrelease. In some cases, enrobing material used in methods and machinesprovided herein can be hydrophilic, which can provide a moist appearanceand/or provide superior flavor release for enrobed consumable productportions. In some cases, methods and machines provided herein canproduce an enrobed smokeless tobacco/tobacco substitute product having alow basis weight web of polymeric fibers, which can be more permeable toflavor release.

Machines for enrobing a product portion provided herein can include atleast one polymer spray head adapted to create a polymer enrobing zoneand a conveyor system adapted to repeatedly move a product portion frombelow a polymer enrobing zone and to above a polymer enrobing zone formultiple passes (e.g., drops) through one or more polymer enrobingzones. A polymer spray head can create a polymer enrobing zone byproducing a plurality of polymeric fibers. In some cases, the polymerspray head can be a melt blowing device, an electro spinning device,and/or a force spinning device. In some cases, the conveyor system isadapted to pass (e.g., drop) each product portion through one or morepolymer enrobing zones a predetermined number of times.

In some cases, the conveyor system is adapted to move at least oneproduct portion from at least one position below a first polymerenrobing zone to at least one position above the first polymer enrobingzone to pass (e.g., drop) each product portion through the first polymerenrobing zone a plurality times. In some cases, the conveyor system isadapted to move each product portion laterally with each pass (e.g.,drop). For example, baffles above or below said first polymer enrobingzone can direct each product portion to slide laterally between eachpass (e.g., drop). In some cases, the conveyor system includes aconveyor belt adapted to move between a position below said firstpolymer enrobing zone and a position above said first polymer enrobingzone. A conveyor belt provided herein can include a plurality of ridgesadapted to inhibit product portions from sliding or rolling backwards onsaid conveyor belt. In some cases, the conveyor system includes one ormore pneumatic conveying tubes.

In some cases, the conveyor system includes a rotary drum positionedaround the at least one polymer spray head. A rotary drum providedherein can move at least one product portion from at least one positionbelow at least one polymer enrobing zone and to at least one positionabove at least one polymer enrobing zone to pass (e.g., drop) eachproduct portion through one or more polymer enrobing zones a pluralitytimes. In some cases, a rotary drum conveyor system can include a sprayguard positioned between said rotary drum and said polymer spray head.In some cases, a collection conveyor positioned within the rotary drumcan collect polymer fibers from said polymer spray head to ensure thatpolymer fibers do not deposit on a surface of the rotary drum. In somecases, a rotary drum conveyor system provided herein can include aportion guide in said rotary drum adapted to ensure that productportions travel around the perimeter of said rotary drum and back intothe at least one polymer enrobing zone. In some cases, the rotary drumcan be tilted to ensure that products exit the drum at a predeterminedend.

In some cases, machines provided herein include multiple polymer sprayheads each creating a separate polymer enrobing zone. A conveyor systemprovided herein can convey one or more product portions passed through afirst polymer enrobing zone from a position below the first polymerenrobing zone to a position above a second polymer enrobing zone to pass(e.g., drop) each product portion through the second polymer enrobingzone. In some cases, machines provided herein include 2 or more polymerenrobing zones, 3 or more polymer enrobing zones, 4 or more polymerenrobing zones, 5 or more polymer enrobing zones, or 6 or more polymerenrobing zones. Conveyor systems provided herein can direct productportions through any number of polymer enrobing zones.

Machines provided herein can include a molding device to mold one ormore product portions. A molding device can be positioned to depositproduct portions on a conveyor adapted to deliver one or more productportions to a position adjacent a polymer enrobing zone.

Methods of enrobing a product portion in polymer strands provided hereincan include directing a plurality of polymeric fibers from a polymerspray head to create at least a first polymer enrobing zone, passing atleast one product portion through the first polymer enrobing zone, andconveying the at least one product portion from a position below thefirst polymer enrobing zone to a position above the first polymerenrobing zone or a second polymer enrobing zone for a second pass (e.g.,a second drop) through a polymer enrobing zone. In some cases, aconveyor belt, a rotary drum, and/or a pneumatic tube are used to movethe at elast one product portion. In some cases, product portion can bemoved such that they have different orientations for different passes(e.g., drops) through polymer enrobing zones relative to the polymerspray head making each polymer enrobing zone. In some cases, each of thefeatures discussed herein regarding the machines provided herein areused in methods provided herein.

Methods and machines provided herein can, in some cases, direct moltenpolymer towards one or more product portions in the polymer enrobingzone such that the molten polymer naturally wraps around the threedimensional product portion. Molten polymer from one or more polymerspray heads can in the polymer enrobing zone can quickly solidify oncecooled to create a random orientation of meshed polymeric fibers thatcompletely wrap the product portion. In some cases, polymeric fibersprovided herein (e.g., polyurethane, polypropylene, etc.) can stick tothemselves after solidifying, which can avoid a need to seal a resultingenrobed product portion. For example, smokeless tobacco product portionsprovided herein can be enrobed in polyurethane and/or polypropylene toform a seamless outer layer, thus avoiding the seams commonly found inconventionally pouched smokeless tobacco products.

Product portions enrobed in methods and machines provided herein can beany suitable product. Product portions enrobed herein can be productswith sufficient integrity to not fall apart when passed through the oneor more polymer enrobing zones. In some cases, product portions enrobedin methods provided herein include consumable products (e.g., tobacco,herbal products such as teas, mint, etc.). In some cases, productportions enrobed in methods provided herein have an overall ovenvolatiles content of about 4% by weight to about 61% by weight. In somecases, a binder can be included in the product portion to have theproduct portion retain its integrity during the enrobing processprovided herein. In some cases, a product portion can include between0.1 and 0.5 weight percent of a binder. Suitable binders include guargum, xanthan gum, cellulose gum, and combinations thereof. In somecases, pre-hydrated Arabic gum can be used in product portions (e.g.,smokeless tobacco products) to act as an emulsifier to increase/improveflavor immediacy.

In some cases, a fiber-wrapped product portion produced using methodsand machines provided herein can include a plurality of polymeric fiberssurrounding the product portion. The polymeric fibers overlying theproduct portion can have a basis weight of 40 grams per square meter(gsm) or less, 30 gsm or less, 20 gsm or less, 10 gsm or less, or 5 gsmor less. The polymeric fibers can have diameters of less than 100microns. In some cases, the polymeric fibers are melt-blown polymericfibers. In some cases, the polymeric fibers are force-spun polymericfibers. In some cases, an electrostatic charge can be applied to theplurality of polymeric fibers, one or more product portions, or acombination thereof. In some cases, a spin is applied to the productportions when passed through the polymer enrobing zone. In some cases,the polymer fibers wrap and seal the body of the product portionssimultaneously. In some cases, combinations of mouth-stable andmouth-dissolvable polymeric materials are combined to form afiber-wrapped product portion that becomes looser when consumed, yetremains generally cohesive. The polymeric fibers can also be a compositeof multiple materials, which may include both mouth-stable andmouth-dissolvable materials.

In some cases, fiber-wrapped smokeless tobacco products produced usingmethods and machines provided herein provide a unique tactile and flavorexperience to an adult tobacco consumer. In particular, the polymericfibers can provide a smoother mouth texture and improved access to thesmokeless tobacco, improved porosity, and improved fluid exchange, ascompared to a traditional pouching material, but still retain thesmokeless tobacco. Moreover, the methods provided herein can result in aseamless wrapping of polymeric fibers, which can reduce mouthirritation. Methods and machines provided herein can also eliminate aneed to separate and seal individual pouches. Furthermore, the polymericfibers provided herein can be more elastic and can permit an adulttobacco consumer to chew/squeeze the fiber-wrapped smokeless tobaccoproduct and mold the product into a desired shape (e.g., to comfortablyconform the product between the cheek and gum). As compared to a typicalpouch paper, the fiber wrappings produced using methods and machinesprovided herein can be softer, have a lower basis weight, and act asless of a selective membrane.

The products and methods described herein can also be applied to otherorally consumable plant materials, in addition to smokeless tobacco. Forexample, some non-tobacco or “herbal” compositions have also beendeveloped as an alternative to smokeless tobacco compositions.Non-tobacco products may include a number of different primaryingredients, including but not limited to, tea leaves, red clover,coconut flakes, mint leaves, citrus fiber, bamboo fiber, ginseng, apple,corn silk, grape leaf, and basil leaf. In some cases, such a non-tobaccosmokeless product can further include tobacco extracts, which can resultin a non-tobacco smokeless product providing a desirable mouth feel andflavor profile. In some cases, the tobacco extracts can be extractedfrom a cured and/or fermented tobacco by mixing the cured and/orfermented tobacco with water and/or other solvents and removing thenon-soluble tobacco material. In some cases, the tobacco extracts caninclude nicotine. In some cases, a pouched non-tobacco product has anoverall oven volatiles content of between 10 weight percent and 61weight percent.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the methods and compositions of matter belong. Althoughmethods and materials similar or equivalent to those described hereincan be used in the practice or testing of the methods and compositionsof matter, suitable methods and materials are described below. Inaddition, the materials, methods, and examples are illustrative only andnot intended to be limiting. All publications, patent applications,patents, and other references mentioned herein are incorporated byreference in their entirety.

DESCRIPTION OF DRAWINGS

FIGS. 1A and 1B depict an exemplary apparatus of a product portionenrobing apparatus provided herein having an elevator design using asingle polymer enrobing zone.

FIG. 2 depicts the method steps of producing an enrobed product portionusing a multiple polymer enrobing zones.

FIG. 3 depicts an exemplary apparatus of a product portion enrobingapparatus provided herein having a waterfall design.

FIG. 4 depicts an exemplary apparatus of a product portion enrobingapparatus provided herein having pneumatic corkscrew design.

FIG. 5 depicts an exemplary apparatus of a product portion enrobingapparatus provided herein having a rotary drum design

FIG. 6A depicts a perspective view of an embodiment of a fiber-wrappedsmokeless tobacco product with a predetermined shape.

FIG. 6B depicts a conventional pouched tobacco product.

FIGS. 7A and 7B illustrate amounts of polymeric fiber deposited on aproduct portion using methods and machines provided herein.

FIG. 8 depicts a chart comparing release rates of methyl sallylate frompouches made of different materials.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

Methods and machines provided herein can be used to enrobe one or moreproduct portions (e.g., smokeless tobacco product portions) withpolymeric fibers. Methods and machines provided herein can be used toefficiently and reliably enrobe multiple product portions whileproviding gentle handling of the product portions. For example,smokeless tobacco portions enrobed by process and machines providedherein can have a high friability prior to enrobing. Methods andmachines provided herein can distribute polymeric fibers onto a productportion evenly across all surfaces of a product portion while minimizingthe strain on the product portions. In some cases, methods and machinesprovided herein can achieve a uniform application of polymeric fibers onall sides of multiple product portions in an automated process.

Methods and machines provided herein pass (e.g. drop) product portionsthrough one or more polymer enrobing zone multiple times at two or moreorientations relative to one or more polymer spray heads to thus receivesubstantially complete coverage of all surfaces. In some cases, productportions can spin or tumble in said polymer enrobing zone. Methods andmachines provided herein can use a variety of techniques to conveyproduct portions from a position below a polymer enrobing zone and to aposition above a polymer enrobing zone. Methods and machines providedherein can be automated to efficiently and reliably enrobe one or moreproduct portions with polymeric fibers using a predetermined number ofpasses (e.g., drops) through one or more polymer enrobing zones. In somecases, machines and methods provided herein include a plurality ofpolymer spray heads, each producing a polymer enrobing zone and eachproduct portion is passed once through each polymer enrobing zone. Insome cases, machines and methods provided herein include a singlepolymer enrobing zone and a conveyor system to repeatedly pass (e.g.,drop) one or more product portions through the single polymer enrobingzone. In some cases, machines provided herein can allow for apredetermined number of passes through a single polymer enrobing zonefor a plurality of product portions by changing a lateral position of adrop position with each successive drop. For example, a lateral positionin a single polymer enrobing zone can be shifted after each pass bypositioning baffles below the single polymer enrobing zone.

Methods and machines provided herein can use any suitable conveyingsystem to move one or more product portions from collection points belowone or more polymer enrobing zones and drop positions above one or morepolymer enrobing zones. In some cases, conveying systems used in methodsand machines provided herein can include a conveyor belt. In some cases,a conveyor belt can include terraces or ridges to limit sliding ofproduct portions on the conveyor belt. Conveyor belts can be drive usingconveyor rollers. In some cases, conveying systems used in methods andmachines provided herein can include pneumatic tubes that can catch oneor more product portions exiting a polymer enrobing zone andpneumatically deliver product portions to a drop position above apolymer enrobing zone. In some cases, a plurality of pneumatic tubes canbe used with one or multiple polymer enrobing zones provide apredetermined path for a product portion. The predetermined path canhave a predetermined number of passes (e.g., drops) through one or morepolymer enrobing zones.

FIGS. 1A and 1B depict an exemplary apparatus of a product portionenrobing apparatus 100 having an elevator design. As shown, theapparatus 100 can include a polymer spray head 110 and polymercollection roller 114 for making a polymer enrobing zone 112 therebetween. Apparatus 100 further includes an elevator conveying systemadapted to move product portions along a predefined path includingmultiple passes (e.g., drops) through polymer enrobing zone 112.Elevator conveying system includes an introduction conveyor 120 todeliver product portions in sequence for a first pass (e.g., a firstdrop) through the polymer enrobing zone 112. After the initial passthrough polymer enrobing zone 112, a partially enrobed product portioncan be collected at collection point 141 and carried on conveyor belts140 and 160 from the collection point 141 to a second drop positionpositioned over the polymer enrobing zone 112. As the product portionsexits polymer enrobing zone 112, the product portions can slidelaterally against inclined baffles 130-139 such that each subsequentdrop position and collection point is laterally spaced from the previousdrop position and collection point. A final baffle 136 can direct afully-enrobed product portion from a final pass through polymer enrobingzone towards a collection conveyor 170.

Elevator conveying system can include conveyor belt 140 and a pluralityof conveyor rollers 151-154. In some cases, elevator conveying systemcan flip product portions between each pass. As shown, elevatorconveying system can include first conveyor belt 140, including aplurality of ridges 142 which define slots 144 for holding one or moreproduct portions. In some cases, multiple laterally spaced productportions are dropped at the same time through polymer enrobing zone 112and collected together in the same slot 144. First conveyor belt 140 caninterface with a second conveyor belt 160 to flip product portions ontosecond conveyor belt 160 for a subsequent pass through polymer enrobingzone. Second conveyor belt 160 can be positioned on rollers 161, 162,163, and 154. Portions of second conveyor belt 160 can sit againstridges 142 as first conveyor belt 140 and second conveyor belt 160 asthey move together against roller 154.

FIG. 2 depicts the method steps of producing an enrobed product portionusing a multiple polymer enrobing zones. In a first step, productportions 204 are molded in cavities of molding device 202 and depositedonto introduction conveyor 220. Introduction conveyor 220 moves multipleproduct portions 204 to a first drop position above first polymerenrobing zone 212 a formed between a first polymer spray head 210 a anda first collection roller 214 a. Partially enrobed product portion 206can land on second conveyor 240 at a first collection point and movepartially enrobed product portion 206 to a second drop position abovesecond polymer enrobing zone 212 b formed between a second polymer sprayhead 210 b and a second collection roller 214 b. Enrobed productportions 208 can land on a collection conveyor 270 at a secondcollection point. Collection conveyor 270 can deliver enrobed productportions 208 to a packaging station.

FIG. 3 depicts an example of a product portion enrobing apparatus 300having a waterfall design. As shown, apparatus 300 forms 4 separatepolymer enrobing zones 312 a, 312 b, 312 c, and 312 d between polymerspray heads 310 a, 310 b, 310 c, and 310 d, and collection rollers 314a, 314 b, 314 c, and 314 d. An introduction conveyor 320, travelingbetween rollers 322 and 324, can deliver a plurality of spaced productportions 304 into a first polymer enrobing zone 312 a. Partially coatedproduct portions can land on first conveyor 340 a after falling throughfirst polymer enrobing zone 312 a and delivered to a drop position abovea second polymer enrobing zone 312 b. Partially coated product portionscan land on second conveyor 340 b after falling through second polymerenrobing zone 312 b and delivered to a drop position above a thirdpolymer enrobing zone 312 c. Partially coated product portions can landon third conveyor 340 c after falling through third polymer enrobingzone 312 c and delivered to a drop position above a fourth polymerenrobing zone 312 d. Enrobed product portions can land on collectionconveyor 370 after falling through fourth polymer enrobing zone 312 d.Collection conveyor 370 can travel between rollers 372 and 374.Collection conveyor 370 can deliver enrobed product portions to apackaging station.

FIG. 4 depicts an exemplary product portion enrobing apparatus 400having corkscrew design. As shown, a single pneumatic tube 440 can beused to collect and deliver a product portion 408 from and to a polymerenrobing zone 412 formed between a polymer spray head 410 and collectionroller 414. A sheet 416 of polymeric fibers can be removed fromcollection roller 414 during the process. Pneumatic tube 440 includes atubular section 442 and a pneumatic pump 446 adapted to deliver an airflow through said pneumatic tube. Collection port 444 can accept aproduct portion 408 after they fall through polymer enrobing zone.Although FIG. 4 only depicts one pneumatic tube loop, machines providedherein can include multiple pneumatic tube loops. In some cases,multiple pneumatic tube loops are positioned such that a product portionbeing dropped from a first pneumatic loop will be collected by a secondpneumatic loop. In some cases, a plurality of pneumatic tube loops canbe arranged to form a helix such that each subsequent drop through thepolymer enrobing zone is laterally spaced from the previous drop. Insome cases, polymer spray head 410 is laterally elongated to accommodatemultiple parallel and simultaneous drops through polymer enrobing zone412.

FIG. 5 depicts an exemplary product portion enrobing apparatus 500having rotary drum design. As shown, rotary drum 540 can be used to moveproduct portions 501 from below one or more polymer enrobing zones 512 aand 512 b formed between one or more polymer spray heads 510 a and 510 band polymer collection conveyor/guard 514. A sheet of polymeric fiberscan be removed from collection conveyor/guard 514 during the process.Rotary drum 540 includes terraces 542 that can help deliver productportions to a position above polymer enrobing zones 512 a and/or 512 bdue to a rotation of the rotary drum 540. Terraces 542 can abut portionguide 544 to ensure that product portions move along the desired path.An introduction conveyor 520 can deliver product portions 501 into abottom portion of rotary drum 540 at a first end of rotary drum 540.Rotary drum 540 rotates to move product portions 501, supported onterraces 542 and/or portion guide 544, to positions above polymerenrobing zones 512 a and/or 512 b. After multiple drops through polymerenrobing zones 512 a and then 512 b, an enrobed product portion 508 canbe collected at a second end of rotary drum 540 on collection conveyor570. Rotary drum can be tilted so that product portions 501 move towardscollection conveyor 570 with each drop such that each product portion isdropped a number of times within a predetermined range (e.g., between 5drops and 25 drops). Introduction conveyor 520 can move on rollers 522and 524. Collection conveyor 572 can move on rollers 572 and 574.

Polymer Spray Head & Polymer Fibers

Polymer spray heads 110, 210 a, 210 b, 310 a-310 d, 410, 510 a, and 510b, in some cases, produce polymeric fibers by melt-blowing, elecrtrospinning, and/or centrifugal force spinning, which are each describedbelow. The polymer can be any suitable polymer usable in a melt-blowingand/or centrifugal force spinning process, such as polypropylene,polyurethane, cellulose, polyethylene, PVC, viscose, EVA (ethyl vinylacetate), polyester, and PLA. In some cases, polymeric fibers 210 can bequenched (i.e., rapidly cooled to below their melt temperature) prior toor upon making contact with product portions dropping through polymerenrobing zones 112, 212 a, 212 b, 312 a-312 d, 412, 512 a, and 512 b.For example, water or other liquid can be sprayed into a polymeric fiberstream as it exits the polymer spray head 110, 210 a, 210 b, 310 a-310d, or 410. In some cases, the polymeric fibers can be quenched with asurfactant, flavor, or other solution. In some cases, the polymericfibers can be cooled to below the melt temperature after contact withproduct portions.

Methods and machines provided herein can, in some cases, enrobe productportions (e.g., smokeless tobacco product portions) in non-woven webs ofelastomeric polymer fibers. In some cases, the use of elastomericpolymers, such as polyurethane, in enrobed smokeless tobacco productsmade using the methods and machines provided herein can provide an adulttobacco consumer with a desirable flavor and tactile experience due toreduced or eliminated seals, improved moldability, controllable flavorrelease, and/or an improved visual appearance as compared to aconventional pouched smokeless tobacco product.

Accordingly, the use of elastomeric polymer fibers (e.g., polyurethanefibers) as an enrobing material in methods and machines provided hereincan produce a smokeless tobacco product having an improved mouth feel ascompared to a conventional pouched product, such as shown in FIG. 6B.Elastomeric polymers can also allow an adult tobacco consumer to moldand/or chew an enrobed smokeless tobacco product in their mouth, whichcan allow for an adult tobacco consumer to both pack and unpack thepacking density of the pouch, which can help control a flavor releaserate. By unpacking a packing density of a pouch, an adult tobaccoconsumer can increase a flavor release rate. Additionally, in somecases, elastomeric polymer fibers can be hydrophilic and have goodwicking properties, thus an enrobed product portion provided herein canhave a moist appearance. Other suitable elastomeric polymers suitablefor methods and machines provided herein include styrenes, Suitableelastomeric polymers include EPAMOULD (Epaflex), EPALINE (Epaflex),TEXIN (Bayer), DESMOPAN (Bayer), HYDROPHAN (AdvanceSourse Biomaterials),ESTANE (Lubrizol), PELLETHANE (Lubrizol), PEARLTHANE (Merquinsa),IROGRAN (Huntsman), ISOTHANE (Greco), ZYTHANE (Alliance Polymers andServices), VISTAMAX (ExxonMobil), and MD-6717 (Kraton). In some cases,elastomers can be combined with polyolefins at ratios ranging from 1:9to 9:1. For example, elastomeric polymers can be combined withpolypropylene. In some cases, a blend of polyurethane, polypropylene,and styrene can be compounded and used to make polymeric fibers inmethods and machines provided herein.

Polyurethane polymers can also provide faster and higher cumulativeflavor release as compared to non-elastic polymer pouch substrates suchas rayon, polypropylene, and polyethylene terephthalate (PET). FIG. 8depicts the cumulative methyl sallcylate concentration (m/portion)measured in artificial saliva fractions from USP-4 flow-throughdissolution pouches made of polyurethane, polypropylene, rayon, and PET.Due to polyurethanes relatively high level of elasticity and naturalhydrophilic properties, flavor is able to traverse polyurethane pouchingmaterial easier than non-elastomeric nonwoven substrates.

In some cases, non-elastomeric polymers can be used in methods andmachines provided herein. Suitable non-elastomeric polymers includerayon, polypropylene, polyethylene, polyethylene terephthalate, andcellulose.

Suitable polymeric materials include one or more of the followingpolymer materials: acetals, acrylics such as polymethylmethacrylate andpolyacrylonitrile, alkyds, polymer alloys, allyls such as diallylphthalate and diallyl isophthalate, amines such as urea, formaldehyde,and melamine formaldehyde, epoxy, cellulosics such as cellulose acetate,cellulose triacetate, cellulose nitrate, ethyl cellulose, celluloseacetate, propionate, cellulose acetate butyrate, hydroxypropylcellulose, methyl hydroxypropyl cellulose (CMC), HPMC, carboxymethylcellulose, cellophane and rayon, chlorinated polyether,coumarone-indene, epoxy, polybutenes, fluorocarbons such as PTFE, FEP,PFA, PCTFE, ECTFE, ETFE, PVDF, and PVF, furan, hydrocarbon resins,nitrile resins, polyaryl ether, polyaryl sulfone, phenol-aralkyl,phenolic, polyamide (nylon), poly (amide-imide), polyaryl ether,polycarbonate, polyesters such as aromatic polyesters, thermoplasticpolyester, PBT, PTMT, (polyethylene terephthalate) PET and unsaturatedpolyesters such as SMC and BMC, thermoplastic polyimide, polymethylpentene, polyolefins such as LDPE, LLDPE, HDPE, and UHMWPE,polypropylene, ionomers such as PD and poly allomers, polyphenyleneoxide, polyphenylene sulfide, polyurethanes (such as DESMOPAN DP 9370Aavailable from Bayer), poly p-xylylene, silicones such as siliconefluids and elastomers, rigid silicones, styrenes such as PS, ADS, SAN,styrene butadiene latricies, and styrene based polymers, suflones suchas polysulfone, polyether sulfone and polyphenyl sulfones, polymericelastomers, and vinyls such as PVC, ethyl vinyl acetate, polyvinylacetate, polyvinylidene chloride, polyvinyl alcohol, polyvinyl butyrate,polyvinyl formal, propylene-vinyl chloride copolymer, ethylvinylacetate, and polyvinyl carbazole, polyvinyl pyrrolidone, andpolyethylene oxide, and ethylene vinyl alcohol, sugar alcohols, andstarches.

Polymeric fibers used on product portions described herein can have adiameter of less than 100 microns, less than 50 microns, less than 30microns, less that 10 microns, less than 5 microns, less than 1 microns,less that 0.5 microns, less than 0.1 microns, less than 0.05 microns, orless than 0.01 microns. In some cases, melt-blown polymeric fibers usedin methods and machines provided herein can have a diameter of between0.5 microns and 5 microns. In some case, force-spun polymeric fibersused in methods and machines provided herein can have a diameter ofbetween 10 nanometers and 1 micron. The flow of the polymeric fibers andthe dimensions of the polymeric fibers as they exit a melt-blowing orcentrifugal force spinning apparatus can result in an intimate contactbetween the fibers and the smokeless tobacco, such that the polymericfibers conform to the surface topography of the fibrous tobaccostructures.

In some cases, polymer spray heads 110, 210 a, 210 b, 310 a-310 d, 410,510 a, and/or 510 b can be a melt-blowing device. Melt-blowing is anextrusion process where molten polymeric resins are extruded through anextrusion die (e.g., a spinneret) and gas is introduced to draw thefilaments to produce polymeric fibers. The gas can be heated air blownat high velocity through orifices that surround each spinneret or in airslots around each individual spinneret. In some cases, layers of hot airare blown through slots between rows of spinnerets—the strands ofpolymeric material are attenuated by being trapped between two layers ofair. Other methods of delivering the attenuating gas (e.g., heated air)are possible. Suitable melt-blowing devices are described in U.S. Pat.Nos. 4,380,570; 5,476,616; 5,645,790; and 6,013,223 and in U.S. PatentApplications US 2004/0209540; US 2005/0056956; US 2009/0256277; US2009/0258099; and US 2009/0258562, which are hereby incorporated byreference. In some cases, some spinnerets can also include orifices thatprovide air flows without polymer to provide additional attenuation anddirection of polymer fibers produced from other spinnerets.

In some cases, polymer spray heads 110, 210 a, 210 b, 310 a-310 d, 410,510 a, and/or 510 b can be a centrifugal force spinning apparatus thatuses centrifugal force to create and orient polymeric fibers. In somecase, polymer spray heads 110, 210 a, 210 b, 310 a-310 d, 410, 510 a,and/or 510 b can include a spinneret that holds polymeric material andis rotated at high speeds with a motor to produce polymeric fibers. Asthe spinneret rotates, the polymeric material (in a liquid state) can bepushed to the orifices lining the outer wall of the spinneret. As thepolymeric material enters the orifice chamber, molecules disentangle andthen align directionally. Centrifugal and hydrostatic forces combine toinitiate a liquid material jet. The external aerodynamic environment,combined with the inertial force of continued rotation, further appliesshear force and promotes cooling and/or solvent evaporation to furtherstretch the fiber. The inertia force can stretch molecular chains intothe nanoscale and the air turbulence can apply a shear force. In somecases, centrifugal force spun fibers can improve a web strength andrandom orientation of polymeric fibers deposited onto a product portiondue to a long fiber length.

In some cases, polymer spray heads 110, 210 a, 210 b, 310 a-310 d, 410,510 a, and/or 510 b can be an electro spinning apparatus that spinsfibers of diameters ranging from 10 nm to several hundred nanometers. Insome cases, electro spun polymers are dissolved in water or organicsolvents. An Electro spinning process makes use of electrostatic andmechanical force to spin fibers from the tip of a fine orifice orspinneret. The spinneret is maintained at positive or negative charge bya DC power supply. When the electrostatic repelling force overcomes thesurface tension force of the polymer solution, the liquid spills out ofthe spinneret and forms an extremely fine continuous filament. Thesefilaments are collected onto a rotating or stationary collector with anelectrode beneath of the opposite charge to that of the spinneret wherethey accumulate and bond together to form nanofiber web.

In some cases, polymeric fibers used in methods and machines providedherein are mouth-stable fibers. The mouth-stable fibers can have lowextractables, are approved for use with food, and/or be manufactured bysuppliers who are GMP approved. Highly desirable are materials that areeasy to process and relatively easy to approve for oral use (e.g.quality, low extractables, approved by regulators, suppliers are GMPapproved). In some cases, the mouth-stable structural fibers areelastomers. Elastomers can provide webs with improved elongation andtoughness. Suitable elastomers include VISTAMAX (ExxonMobil), TEXINRXT70A (Bayer), and MD-6717 (Kraton). In some cases, elastomers can becombined with polyolefins at ratios ranging from 1:9 to 9:1. Forexample, elastomers (such as VISTAMAX or MD-6717) can be combined withpolypropylene.

Mouth-dissolvable fibers could be made from hydroxypropyl cellulose(HPC), methyl hydroxypropyl cellulose (HPMC), polyvinyl alcohol (PVOH),PVP, polyethylene oxide (PEO), starch and others. Fibers 210 can in somecases include contain flavors, sweeteners, milled tobacco, and otherfunctional ingredients. In some cases, mouth-dissolvable fibers can becombined with mouth-stable fibers to enrobe the product portions asprovided herein.

Colorants and/or fillers can also be added to the polymer in polymerspray heads 110, 210 a, 210 b, 310 a-310 d, 410, 510 a, and/or 510 b.The hydraulic permittivity of the enrobing coating of polymeric fiberscan also be increased by compounding the polymer with filler prior toforming the polymeric fibers. The hydraulic permittivity is the rate offluid transfer through a substrate. In some cases, a colorant can beused as the filler. For example, a brown colorant can be added to a feedhopper of an extruder along with a polymer material (e.g., polypropyleneor polyurethane) prior to melt-blowing the polymer into the fibers. Inaddition to improving the hydraulic permittivity, the colorant canimprove the aesthetic appeal of the fiber-wrapped product portion. Forexample, a brown colorant can make a wrapped moist-smokeless tobaccoproduct appear moist.

As discussed above, the polymeric fibers can contact the productportions at a temperature greater than the melt temperature of thepolymer. In some cases, however, the polymeric fibers can be quenchedand/or treated with a surfactant prior to contacting the productportions. Water vapor can be used to cool the polymeric material. Forexample, atomized water from a spout can be directed into a stream ofmolten strands of polymeric material exiting polymer spray heads 110,210 a, 210 b, 310 a-310 d, 410, 510 a, and/or 510 b to “quench” thepolymeric strands and form the fibers. For example, a mist can be aimedtowards spinnerets of the melt-blowing spray head. A fine mist of wateror surfactant or air can quickly cool the strands below the polymer'smelt temperature. In some cases, quenched melt-blown fibers can haveimproved softness and fiber/web tensile strength.

A surfactant treatment can also be applied to polymeric fibers used inthe methods and machines provided herein. In some cases, a surfactant isapplied to the polymeric fibers as they exit the spinnerets of polymerspray heads 110, 210 a, 210 b, 310 a-310 d, 410, 510 a, and/or 510 b. Insome cases, surfactant can be applied as a mist (either with or withoutwater). In some cases, the surfactant applied as a mist can quench thepolymeric fibers. In some cases, the surfactant can be applied in anextrusion process. In some cases, a mixture of water and surfactant canbe atomized and applied as mist.

Quenching the polymer can modify the crystallinity of the polymermaterial to improve tensile strength and mouth feel. The surfactant canimprove the hydraulic permittivity of the coating of polymeric fibers(e.g., to improve moisture and flavor release from an enrobed smokelesstobacco product). The hydraulic permittivity is the rate of fluidtransfer through a substrate. Sweeteners and/or flavorants can also beatomized and applied to the polymeric fibers as mist to quench thefibers.

The tensile integrity of the wrapped fiber can also be improved bybonding fibers together. In some cases, the wrapped fiber can be heatbonded at intersection points. The heating of the polymeric material toa temperature above its melt temperature can be accomplished by usingelectrically heated surfaces, ultrasonic bonding, infrared energy, radiofrequency energy, microwave energy, laser, and/or needle punching.Stitch bonding, point bonding, and quilting are methods of applyingpatterns to nonwoven fabrics. These are forms of thermal bondingtypically achieved with ultrasonic bonding processes, although otherenergy sources and related equipment can be used to create particularpatterns of bonding within the network of fibers.

The amount of polymeric material used depends on the final use of theenrobed product portion. For an enrobed smokeless tobacco product, theamount can depend on the desired flavor profile and desired mouth feel.In some cases, an enrobed product portion includes less than 200 mg ofpolymer per product portion. In some cases, a single enrobed productportion can include between 1 and 100 mg of polymeric material, between60 and 80 mg of polymeric material, between 10 and 50 mg of polymericmaterial, or between 25 and 75 mg of polymeric material. In some cases,an enrobed product portion includes between 0.1% and 10% by weight ofpolymeric material, between 0.4% and 5% by weight of polymeric material,between 0.5% and 2% by weight of polymeric material, between 2% and 4%by weight of polymeric material, or between 1% and 3% by weight ofpolymeric material. In some cases, the basis weight of the wrapping ofpolymeric fibers on an enrobed product portion can have a basis weightof less than 30 gsm, less than 25 gsm, less than 20 gsm, less than 15gsm, less than 10 gsm, less than 5 gsm, less than 4 gsm, less than 3gsm, less than 2 gsm, or less than 1 gsm. In some cases, the wrapping ofpolymeric fibers on an enrobed product portion can have a basis weightof between 0.5 gsm and 4 gsm, between 1 gsm and 3 gsm, or of about 2gsm.

FIGS. 7A and 7B illustrate an amount of polymeric fiber coated onto aproduct portion based on a number of drops through a polymer enrobingzone. FIG. 7A depicts an amount of polymeric fiber 782, removed from aproduct portion, deposited on a product portion after 5 drops through apolymer enrobing zone. Polymeric fiber 784 is an amount of polymericfiber deposited on a product portion after 25 drops through a polymerenrobing zone. FIG. 7B graphically displays the relationship between anumber of drops and the coating weigh. In some cases, an enrobed productportion provided herein (e.g., an enrobed smokeless tobacco product)includes between 1.5 mg and 4.0 mg of polymeric fiber.

Enrobed Product Portions

Methods and machines provided herein can be used to enrobe any suitableproduct portion. Methods and machines provided herein can be useful tocoat and contain any fragile body. Exemplary products that can beenrobed in polymeric fibers using a method or machine provided hereininclude smokeless tobacco products and smokeless tobacco substitutes,herbal and spice products, and teas and other beverage producingmixtures. Polymeric-fiber enrobed smokeless tobacco portions aredescribed below. Smokeless tobacco substitutes can include herbalproducts that provide a satisfying flavor without tobacco and/ornicotine. For example, in some cases, mixtures of herbs and spices (withor without nicotine) can provide an adult tobacco consumer with a flavorand tactile experience similar to the use of a smokeless tobaccoproduct. In some cases, cellulosic fibers can be mixed with flavors,nicotine, and other additives to provide a flavor and tactile experiencesimilar to the use of a smokeless tobacco product. In some cases, herbaland/or spice mixes can be enrobed in polymeric fibers in a method ormachine provided herein to be used in preparing meals and/or beverages.For example, a spice package for a stew can include ingredients such asbay leaf that should be removed from the stew after cooking. In somecases, herbal beverages (e.g., black tea, green tea, etc.) can beenrobed in polymeric fibers using a method and/or machine providedherein to provide an herbal beverage brewing bag (e.g., a tea bag, acoffee pod).

Suitable herbs and other edible plants can be categorized generally asculinary herbs (e.g., thyme, lavender, rosemary, coriander, dill, mint,peppermint) and medicinal herbs (e.g., Dahlias, Cinchona, Foxglove,Meadowsweet, Echinacea, Elderberry, Willow bark). In some cases, thetobacco is replaced with a mixture of non-tobacco plant material. Suchnon-tobacco compositions may have a number of different primaryingredients, including but not limited to, tea leaves, coffee, redclover, coconut flakes, mint leaves, ginseng, apple, corn silk, grapeleaf, and basil leaf. The plant material typically has a total ovenvolatiles content of about 10% by weight or greater; e.g., about 20% byweight or greater; about 40% by weight or greater; about 15% by weightto about 25% by weight; about 20% by weight to about 30% by weight;about 30% by weight to about 50% by weight; about 45% by weight to about65% by weight; or about 50% by weight to about 60% by weight.

Polymeric Fiber Enrobed Smokeless Tobacco Product Portion

A fiber-wrapped smokeless tobacco portion can retain the smokelesstobacco fibers when placed in an adult tobacco consumer's mouth, yetallow the flavors and substances of the tobacco to pass through thepolymeric fibers. FIG. 6A depicts an exemplary polymeric fiber enrobedsmokeless tobacco portion 600. In some cases, polymeric fibers onpolymeric fiber enrobed smokeless tobacco portion 600 have a diameter ofless than 100 microns. Polymeric fibers wrapped around the smokelesstobacco can form a moisture-permeable porous surface that can provide aunique tactile and flavor experience to an adult tobacco consumer. Inparticular, polymeric fibers can provide a smooth mouth texture,bind/encase/encapsulate the smokeless tobacco during use, but give theadult tobacco consumer good access to the smokeless tobacco and anyflavor contained therein. As compared to a typical pouch paper, thepolymeric fibers can be softer, be free of seams, have a lower basisweight, act as less of a selective membrane, be chewable, and havegreater moldability/manageability. The methods and machines providedherein can be used to produce a polymeric fiber enrobed smokelesstobacco portion 600 that remains cohesive and are less likely to breakapart during packaging, handling, shipping, and during use by adulttobacco consumers. In some cases, polymeric fibers can provide a softand highly porous coating around the smokeless tobacco. Methods andmachines provided herein can enrobe and/or wrap smokeless tobaccos thatare not suitable for being pouched using a typical pouching operation;for example, smokeless tobaccos having an average partial aspect ratioof greater than 3 (e.g., long-cut smokeless tobacco) and/or highmoisture tobacco (e.g., a tobacco having an OV content of greater than47 weight percent).

The described combinations of the polymeric material and smokelesstobacco can provide a softer mouth feel. Moreover, in some cases, thepolymeric material can be elastic or pliable (e.g., a polymericpolyurethane such as DESMOPAN DP 9370A available from Bayer), thusforming a smokeless tobacco product that can tolerate being “worked”(e.g., chewed or squeezed) in the mouth without the tobacco dispersingwithin the mouth. For example, the smokeless tobacco product can beworked to provide flavor and/or to comfortably conform between the cheekand gum. In some cases, combinations of mouth-stable andmouth-dissolvable polymeric materials are combined with a body includingsmokeless tobacco material to provide a product that becomes looserafter being placed in an adult tobacco consumer's mouth, yet remainsgenerally cohesive. Polymeric structural fibers can also be a compositeof multiple materials, which may include both mouth-stable andmouth-dissolvable materials.

Polymeric fiber enrobed smokeless tobacco portion 600 can includepolymeric structural fibers formed of polymeric fibers deposited using amethod or machine provided herein that forms a nonwoven network againstand around a body of smokeless tobacco material. As used herein, theterm “nonwoven” means a material made from fibers that are connected byentanglement and/or bonded together by a chemical, heat, or solventtreatment where the material does not exhibit the regular patterns of awoven or knitted fabric. Polymeric fiber enrobed smokeless tobaccoportions 600 can also be dimensionally stable. As used herein,“dimensionally stable” means that the fiber-wrapped smokeless tobaccoproduct retains its shape under its own weight. In some cases, polymericfiber enrobed smokeless tobacco portions 600 are flexible, yet can bepicked up at one end without the force of gravity causing the polymericfiber enrobed smokeless tobacco portions 600 to bend or sag. In somecases, polymeric fiber enrobed smokeless tobacco portions 600 can beeasily deformable.

Individual product portions of smokeless tobacco for use in a method ormachine provided herein can be made using any suitable method. Forexample, smokeless tobacco can be added to a mixer and mixed withoptional binder(s), and optional flavorants, and/or other additives. Forexample, the smokeless tobacco can be long cut tobacco, having an ovenvolatiles content of 10-61 weight percent. In some cases, an addedbinder can be TICALOID LITE Powder. In some cases, an added flavorantsand/or other additives can include, for example, a mint flavoring, asweetener, and a pH modifier. The mixing can occur in any commerciallyavailable countertop mixer or industrial mixer, for example a HOBART 40lbs mixer or a FORBERG 250 lbs Paddle Mixer. Water can be added to thetobacco prior to or during the mixing process to alter the total ovenvolatiles content. The oven volatiles content can also be modified byheating the mixture. In some cases, a commercially available smokelesstobacco product (e.g., SKOAL Long Cut) can be mixed with a binder (e.g.,TICALOID LITE Powder) to form the mixture, which can then be shaped intoone or more bodies used as product portions in methods and machinesprovided herein.

In some cases, bodies of smokeless tobacco used as product portions inmethods and machines provided herein can have less than 1% by weight ofbinder, less than 0.5% by weight of binder, less than 0.3% by weight ofbinder, less than 0.2% by weight of binder, less than 0.1% by weight ofbinder, or less than 0.05% by weight of binder. In some cases, bodies ofsmokeless tobacco used as product portions in methods and machinesprovided herein include one or more binders, such as a hydrocolloid, inan amount of between 0.05 weight percent and 0.8 weight percent. In somecases, bodies of smokeless tobacco used as product portions in methodsand machines provided herein include between 0.1 and 0.5 weight percentbinder. For example, bodies of smokeless tobacco used as productportions in methods and machines provided herein can include between 0.2and 0.4 weight percent of a binder that includes guar gum, xanthan gum,cellulose gum, or similar materials or a combination thereof.

The molding of a product portion out of smokeless tobacco can includedepositing a smokeless tobacco containing mixture into a mold. In somecases, a smokeless tobacco containing mixture is deposited into an openmold plate including a plurality of identically shaped cavities. Amolding process can include applying pressure to a smokeless tobaccocontaining mixture. This pressure can be applied as injection pressureapplied to the mixture as it is forced into a closed cavity or bycompressing each cavity filled with the mixture. The pressure usedduring the molding process impacts that amount of compressionexperienced by the mixture and thus the material properties of themixture. In some cases, 50-300 lbs. of injection pressure is used todeliver a smokeless tobacco containing mixture into a plurality of moldcavities. The molds can be filled with continuous or intermittentpressure. A screw pump can be used to apply the pressure to a smokelesstobacco containing mixture. For example, a FORMAX® machine (e.g., theFORMAX F-6 and F-19 units) can be used to inject a smokeless tobaccocontaining mixture into cavities in a mold plate. For example, such aprocess is described in U.S. Patent Application Publication No.2012/0024301, which is hereby incorporated by reference. In some cases,the mold cavities have a volume sized to create shaped smokeless tobaccobodies having a mass of, for example, about 2.35 grams. The edges andcorners of the mold can be rounded to permit the shaped smokelesstobacco bodies to be easily released from the mold and be comfortable inthe mouth of an adult tobacco consumer. In some cases, a molding stepcan include extruding smokeless tobacco material (optionally withbinders, flavorants, and other additives), and cutting the extrudedsmokeless tobacco material to form product portions.

The polymer used in polymeric fiber enrobed smokeless tobacco portion600 can be any of the polymers discussed above. In some cases, polymericfiber enrobed smokeless tobacco portion 600 is polyurethane and/orpolypropylene. Binders suitable for use in the polymeric fiber enrobedsmokeless tobacco portion 600 provided herein include orally compatiblepolymers, such as cellulosics (e.g., carboxymethyl cellulose (CMC),hydroxypropyl cellulose (HPC), hydroxyethyl cellulose (HEC),hydroxypropyl methyl cellulose (HPMC), and methyl cellulose (MC));natural polymers (e.g., starches and modified starches, konjac,collagen, inulin, soy protein, whey protein, casein, and wheat gluten);seaweed-derived polymers (e.g., carrageenan (kappa, iota, and lambda);alginates, (and propylene glycol alginate), microbial-derived polymers(e.g., xanthan, dextrin, pullulan, curdlan, and gellan); extracts (e.g.,locust bean gum, guar gum, tara gum, gum tragacanth, pectin (lo methoxyand amidated), agar, zein, karaya, gelatin, psyllium seed, chitin, andchitosan), exudates (e.g., gum acacia (arabic) and shellac), syntheticpolymers (e.g., polyvinyl pyrrolidone, polyethylene oxide, and polyvinylalcohol. Flavors and other additives can be included in polymeric fiberenrobed smokeless tobacco portion 600 described herein and can be addedto polymeric fiber enrobed smokeless tobacco portion 600 at any point inthe process of making the polymeric fiber enrobed smokeless tobaccoportion 600. Suitable flavorants include wintergreen (i.e., methylsalicylate), cherry and berry type flavorants, various liqueurs andliquors such as Dramboui, bourbon, scotch, whiskey, spearmint,peppermint, lavender, cinnamon, cardamon, apium graveolents, clove,cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, roseoil, vanilla, lemon oil, orange oil, Japanese mint, cassia, caraway,cognac, jasmin, chamomile, menthol, ilangilang, sage, fennel, piment,ginger, anise, coriander, coffee, liquorish, and mint oils from aspecies of the genus Mentha. Mint oils useful in some cases of thefiber-wrapped smokeless tobacco products include spearmint andpeppermint. Flavorants can also be included in the form of flavor beads(e.g., flavor capsules, flavored starch beads, flavored gelatin beads),which can be dispersed within the fiber-wrapped smokeless tobaccoproduct (e.g., in a nonwoven network of polymeric structural fibers).For example, the fiber-wrapped smokeless tobacco product could includethe beads described in U.S. Patent Application Publication 2010/0170522,which is hereby incorporated by reference. Other optional additivesincluded as fillers (e.g., starch, di-calcium phosphate, lactose, beetfiber (FIBREX), sorbitol, mannitol, and microcrystalline cellulose),soluble fiber (e.g., FIBERSOL from Matsushita), calcium carbonate,dicalcium phosphate, calcium sulfate, and clays), lubricants (e.g.,lecithin, stearic acid, hydrogenated vegetable oil, canola oil, mineraloil, polyethylene glycol 4000-6000 (PEG), sodium lauryl sulfate (SLS),glyceryl palmitostearate, sodium benzoate, sodium stearyl fumarate,talc, and stearates (e.g., Mg or K), and waxes (e.g., glycerolmonostearate, propylene glycol monostearate, and acetylatedmonoglycerides), plasticizers (e.g., glycerine), propylene glycol,polyethylene glycol, sorbitol, mannitol, triacetin, and 1,3 butanediol), stabilizers (e.g., ascorbic acid and monosterol citrate, BHT, orBHA), artificial sweeteners (e.g., sucralose, saccharin, and aspartame),disintegrating agents (e.g., starch, sodium starch glycolate, crosscaramellose, cross linked PVP), pH stabilizers, salt, or other compounds(e.g., vegetable oils, surfactants, and preservatives). Some compoundsdisplay functional attributes that fall into more than one of thesecategories. For example, propylene glycol can act as both a plasticizerand a lubricant, and sorbitol can act as both a filler and aplasticizer.

Smokeless tobacco is tobacco suitable for use in an orally used tobaccoproduct. By “smokeless tobacco” it is meant a part, e.g., leaves, andstems, of a member of the genus Nicotiana that has been processed.Exemplary species of tobacco include N. rustica, N. tabacum, N.tomentosiformis, and N. sylvestris. Suitable tobaccos include fermentedand unfermented tobaccos. In addition to fermentation, the tobacco canalso be processed using other techniques. For example, tobacco can beprocessed by heat treatment (e.g., cooking, steam treating, toasting),flavoring, enzyme treatment, expansion, and/or curing. Both fermentedand non-fermented tobaccos can be processed using these techniques.

Tobacco can be conditioned by heating, sweating and/or pasteurizingsteps as described in U.S. Publication Nos. 2004/0118422 or2005/0178398. In some cases, the tobacco can be unprocessed tobacco.Specific examples of suitable processed tobaccos include, darkair-cured, dark fire-cured, burley, flue cured, and cigar filler orwrapper, as well as the products from the whole leaf stemming operation.In some cases, smokeless tobacco includes up to 70% dark tobacco on afresh weight basis. Fermenting typically is characterized by highinitial moisture content, heat generation, and a 10 to 20% loss of dryweight. See, e.g., U.S. Pat. Nos. 4,528,993; 4,660,577; 4,848,373; and5,372,149. In addition to modifying the aroma of the leaf, fermentationcan change the color, texture, taste, and sensorial attributes of aleaf. Also during the fermentation process, evolution gases can beproduced, oxygen can be taken up, the pH can change, and the amount ofwater retained can change. See, for example, U.S. Publication No.2005/0178398 and Tso (1999, Chapter 1 in Tobacco, Production, Chemistryand Technology, Davis & Nielsen, eds., Blackwell Publishing, Oxford).Cured, or cured and fermented tobacco, can be further processed (e.g.,cut, expanded, blended, milled or comminuted) prior to incorporationinto the smokeless tobacco product. The tobacco, in some cases, is longcut fermented cured moist tobacco having an oven volatiles content ofbetween 10 and 61 weight percent prior to mixing with the polymericmaterial and optionally flavorants and other additives.

The tobacco can, in some cases, be prepared from plants having less than20 μg of DVT per cm² of green leaf tissue. For example, the tobaccoparticles can be selected from the tobaccos described in U.S. PatentPublication No. 2008/0209586, which is hereby incorporated by reference.Tobacco compositions containing tobacco from such low-DVT varietiesexhibits improved flavor characteristics in sensory panel evaluationswhen compared to tobacco or tobacco compositions that do not havereduced levels of DVTs.

Green leaf tobacco can be cured using conventional means, e.g.,flue-cured, barn-cured, fire-cured, air-cured, or sun-cured. See, forexample, Tso (1999, Chapter 1 in Tobacco, Production, Chemistry andTechnology, Davis & Nielsen, eds., Blackwell Publishing, Oxford) for adescription of different types of curing methods. Cured tobacco isusually aged in a wooden drum (i.e., a hogshead) or cardboard cartons incompressed conditions for several years (e.g., two to five years), at amoisture content ranging from 10% to about 25%. See, U.S. Pat. Nos.4,516,590 and 5,372,149. Cured and aged tobacco then can be furtherprocessed. Further processing includes conditioning the tobacco undervacuum with or without the introduction of steam at varioustemperatures, pasteurization, and fermentation. Fermentation istypically characterized by high initial moisture content, heatgeneration, and a 10% to 20% loss of dry weight. See, e.g., U.S. Pat.Nos. 4,528,993, 4,660,577, 4,848,373, 5,372,149; U.S. Publication No.2005/0178398; and Tso (1999, Chapter 1 in Tobacco, Production, Chemistryand Technology, Davis & Nielsen, eds., Blackwell Publishing, Oxford).Cure, aged, and fermented smokeless tobacco can be further processed(e.g., cut, shredded, expanded, or blended). See, for example, U.S. Pat.Nos. 4,528,993; 4,660,577; and 4,987,907.

The smokeless tobacco can be processed to a desired size. For example,long cut smokeless tobacco typically is cut or shredded into widths ofabout 10 cuts/inch up to about 110 cuts/inch and lengths of about 0.1inches up to about 1 inch. Double cut smokeless tobacco can have a rangeof particle sizes such that about 70% of the double cut smokelesstobacco falls between the mesh sizes of −20 mesh and 80 mesh. Otherlengths and size distributions are also contemplated.

The smokeless tobacco can have a total oven volatiles content of about10% by weight or greater; about 20% by weight or greater; about 40% byweight or greater; about 15% by weight to about 25% by weight; about 20%by weight to about 30% by weight; about 30% by weight to about 50% byweight; about 45% by weight to about 65% by weight; or about 50% byweight to about 60% by weight. Those of skill in the art will appreciatethat “moist” smokeless tobacco typically refers to tobacco that has anoven volatiles content of between about 40% by weight and about 60% byweight (e.g., about 45% by weight to about 55% by weight, or about 50%by weight). As used herein, “oven volatiles” are determined bycalculating the percentage of weight loss for a sample after drying thesample in a pre-warmed forced draft oven at 110 degrees C. for 3.25hours. The fiber-wrapped smokeless tobacco product can have a differentoverall oven volatiles content than the oven volatiles content of thesmokeless tobacco used to make the fiber-wrapped smokeless tobaccoproduct. The processing steps described herein can reduce or increasethe oven volatiles content. The overall oven volatiles content of thefiber-wrapped smokeless tobacco product is discussed below.

Polymeric fiber enrobed smokeless tobacco portion 600 can includebetween 15 weight percent and 85 weight percent smokeless tobacco on adry weight basis. The amount of smokeless tobacco in polymeric fiberenrobed smokeless tobacco portion 600 on a dry weight basis iscalculated after drying polymeric fiber enrobed smokeless tobaccoportion 600 in a pre-warmed forced draft oven at 110 degrees C. for 3.25hours. The remaining non-volatile material is then separated intotobacco material and polymeric material. The percent smokeless tobaccoin the fiber-wrapped smokeless tobacco product is calculated as theweight smokeless tobacco divided by the total weight of the non-volatilematerials. In some cases, the fiber-wrapped smokeless tobacco productincludes between 20 and 60 weight percent tobacco on a dry weight basis.In some cases, polymeric fiber enrobed smokeless tobacco portion 600includes at least 28 weight percent tobacco on a dry weight basis. Forexample, polymeric fiber enrobed smokeless tobacco portion 600 caninclude a total oven volatiles content of about 57 weight percent, about3 weight percent polymeric material, and about 40 weight percentsmokeless tobacco on a dry weight basis.

Polymeric fiber enrobed smokeless tobacco portion 600 can have a totaloven volatiles content of between 10 and 61 weight percent. In somecases, the total oven volatiles content is at least 40 weight percent.The oven volatiles include water and other volatile compounds, which canbe a part of the tobacco, the polymeric material, the flavorants, and/orother additives. As used herein, the “oven volatiles” are determined bycalculating the percentage of weight loss for a sample after drying thesample in a pre-warmed forced draft oven at 110 degrees C. for 3.25hours. Some of the processes may reduce the oven volatiles content(e.g., heating the composite or contacting the smokeless tobacco with aheated polymeric material), but the processes can be controlled to havean overall oven volatiles content in a desired range. For example, waterand/or other volatiles can be added back to the fiber-wrapped smokelesstobacco product to bring the oven volatiles content into a desiredrange. In some cases, the oven volatiles content of polymeric fiberenrobed smokeless tobacco portion 600 is between 4 and 61 weightpercent. In some cases, the oven volatiles content of polymeric fiberenrobed smokeless tobacco portion 600 is between 47 and 61 weightpercent. For example, the oven volatiles content of smokeless tobaccoused in the various processed described herein can be about 57 weightpercent. In some cases, the oven volatiles content can be between 10 and30 weight percent. In some cases, enrobed product portions produced inmethods and/or machines provided herein can be rewet with water and/or asolution of flavorants, sweeteners, and/or other additives discussedherein to wick the coating of polymeric fibers, provide a moistappearance, prove a flavor immediately, and/or to increase a flavorintensity.

Some embodiments of a smokeless tobacco system can include one or morepolymeric fiber enrobed smokeless tobacco portion 600. A plurality ofpolymeric fiber enrobed smokeless tobacco portions 500 can be arrangedin an interior space of a bottom container that mates with a lid. Theplurality of the polymeric fiber enrobed smokeless tobacco portions 500arranged in the container can all have a substantially similar shape sothat an adult tobacco consumer can conveniently select any of thesimilarly shaped polymeric fiber enrobed smokeless tobacco portions 500therein and receive a generally consistent portion of the smokelesstobacco.

An exemplary shape of a polymeric fiber enrobed smokeless tobaccoportion 600 provided herein is shown in FIG. 6A, which depicts aperspective view of polymeric fiber enrobed smokeless tobacco portion600 having a substantially rectangular cuboidal shape with roundedcorners in the longitudinal (lengthwise) plane. In some cases, polymericfiber enrobed smokeless tobacco portion 600 has a substantiallyrectangular cuboidal shape having a length of between 15 mm and 50 mm, awidth of between 5 mm and 20 mm, and a thickness of between 3 mm and 12mm. For example, a substantially rectangular cuboidal shape could have alength of between 26 mm and 30 mm, a width of between 10 mm and 12 mm,and a thickness of between 6 mm and 8 mm. A product having a length of28 mm, a width of 11 mm, and thickness of 7 mm could have a productweight of about 2.35 g. In other embodiments, a substantiallyrectangular cuboidal shape could have a length of between 18 and 21 mm,a width of between 10 mm and 12 mm, and a thickness of between 9 mm and11 mm. In some cases, the preformed smokeless tobacco product can becube shaped. Other shapes and sizes are also contemplated. For example,polymeric fiber enrobed smokeless tobacco portion 600 can be configuredto be: (A) an elliptical shaped fiber-wrapped smokeless tobacco product;(B) an elongated elliptical shaped fiber-wrapped smokeless tobaccoproduct; (C) a semi-circular fiber-wrapped smokeless tobacco product;(D) a square- or rectangular-shaped fiber-wrapped smokeless tobaccoproduct; (E) a football-shaped fiber-wrapped smokeless tobacco product;(F) an elongated rectangular-shaped fiber-wrapped smokeless tobaccoproduct; (G) boomerang-shaped fiber-wrapped smokeless tobacco product;(H) a rounded-edge rectangular-shaped fiber-wrapped smokeless tobaccoproduct; (I) teardrop- or comma-shaped fiber-wrapped smokeless tobaccoproduct; (J) bowtie-shaped fiber-wrapped smokeless tobacco product; and(K) peanut-shaped fiber-wrapped smokeless tobacco product. Polymericfiber enrobed smokeless tobacco portion 600 can have differentthicknesses or dimensionality, such that a beveled fiber-wrappedsmokeless tobacco product (e.g., a wedge) is produced or ahemi-spherical shape is produced.

OTHER EMBODIMENTS

It is to be understood that, while the invention has been describedherein in conjunction with a number of different aspects, the foregoingdescription of the various aspects is intended to illustrate and notlimit the scope of the invention, which is defined by the scope of theappended claims. Other aspects, advantages, and modifications are withinthe scope of the following claims.

Disclosed are methods and compositions that can be used for, can be usedin conjunction with, can be used in preparation for, or are products ofthe disclosed methods and compositions. These and other materials aredisclosed herein, and it is understood that combinations, subsets,interactions, groups, etc. of these methods and compositions aredisclosed. That is, while specific reference to each various individualand collective combinations and permutations of these compositions andmethods may not be explicitly disclosed, each is specificallycontemplated and described herein. For example, if a particularcomposition of matter or a particular method is disclosed and discussedand a number of compositions or methods are discussed, each and everycombination and permutation of the compositions and the methods arespecifically contemplated unless specifically indicated to the contrary.Likewise, any subset or combination of these is also specificallycontemplated and disclosed.

What is claimed is:
 1. An oral product comprising: a body includingtobacco fibers; and a porous wrap surrounding the body and having abasis weight of less than or equal to 40 grams per square meter, theporous wrap including, a plurality of fibers including, a polymer, and afiller configured to increase a hydraulic permittivity of the porouswrap.
 2. The oral product of claim 1, wherein the tobacco fibers have anaverage particle aspect ratio of greater than
 3. 3. The oral product ofclaim 1, wherein the tobacco fibers have a total oven volatiles contentranging from 45% by weight to 65% by weight.
 4. The oral product ofclaim 1, wherein the polymer includes an elastomer.
 5. The oral productof claim 4, wherein the elastomer includes polyurethane.
 6. The oralproduct of claim 1, wherein at least a portion of the fibers of theplurality of fibers have a diameter of less than 100 microns.
 7. Theoral product of claim 6, wherein the diameter ranges from 0.5 microns to5 microns.
 8. The oral product of claim 6, wherein the diameter rangesfrom 10 nanometer to 1 micron.
 9. The oral product of claim 1, whereinthe plurality of fibers are non-woven.
 10. The oral product of claim 1,wherein the polymer is hydrophilic.
 11. The oral product of claim 1,wherein the polymer is mouth-stable.
 12. The oral product of claim 1,wherein the filler includes a colorant.
 13. The oral product of claim12, wherein the colorant includes a brown colorant.
 14. The oral productof claim 1, wherein the polymer is present in an amount less than orequal to 200 mg.
 15. An oral product comprising: a body including,non-tobacco cellulosic fibers, and nicotine; and a porous wrapsurrounding the body and having a basis weight of less than or equal to40 grams per square meter, the porous wrap including, a plurality offibers including, a polymer, and a filler configured to increase ahydraulic permittivity of the porous wrap.
 16. The oral product of claim15, wherein the non-tobacco cellulosic fibers have an average particleaspect ratio of greater than
 3. 17. The oral product of claim 15,wherein the non-tobacco cellulosic fibers have a total oven volatilescontent ranging from 45% by weight to 65% by weight.
 18. The oralproduct of claim 15, wherein the polymer includes an elastomer.